Method of making a bellhousing

Abstract

A method of making an engine transmission bellhousing includes the steps of making the pattern for sandcasting a bellhousing having an engine attaching flange portion shaped to cover the engine bolt holes in a plurality of different engines, and making a mold using the pattern for sandcasting a bellhousing. Then selecting an aluminum alloy having the strength and characteristics selected to eliminate a bellhousing flexplate, which aluminum alloy includes aluminum alloyed with either zinc or silicon and selected other elements in lesser quantity and then casting the engine and bellhousing in the sand mold made with the bellhousing pattern. A plurality of flange bolt holes is formed in the flange of the bellhousing either as part of the casting or by a separate drilling operation with the predetermined bolt holes positioned for alignment with the engine bellhousing bolt holes in any one of a plurality of different engines with the remaining flange bolt holes not in alignment with the particular engine bellhousing bolt holes so that a cast bellhousing eliminates the flex plate and fits a plurality of different engines.

I claim: 
     
       1. A method of making an engine transmission bell housing comprising the steps of: making a pattern for casting a bellhousing having an engine attaching flange portion shaped to cover the engine bolt holes in a plurality of different engines;   making a mold using the pattern made for casting a bellhousing;   selecting an aluminum alloy having a strength selected to eliminate a bell housing flexplate, said selected aluminum alloy including aluminum alloyed with zinc;   casting an engine bell housing in said mold made with said bell housing pattern; and   forming a plurality of flange bolt holes in the flange of said bell housing with predetermined ones of said plurality of bolt holes positioned for alignment with the engine bell housing bolt holes in any one of a plurality of different engines and some of said plurality of flange bolt holes being out of alignment with the engine bell housing bolt holes of a plurality of engines, whereby a cast bell housing eliminates the flexplate and fits a plurality of different engines.   
     
     
       2. A method of making an engine transmission bell housing in accordance with claim 1 in which the step of selecting an aluminum alloy includes selecting an alloy of aluminum having at least 5% zinc. 
     
     
       3. A method of making an engine transmission bell housing in accordance with claim 1 in which the step of selecting an aluminum alloy includes selecting an alloy of aluminum having at least 1% iron. 
     
     
       4. A method of making an engine transmission bell housing in accordance with claim 3 in which the step of selecting an aluminum alloy includes selecting an alloy of aluminum having nickel, tin, Manganese and Magnesium alloyed therewith. 
     
     
       5. A method of making an engine transmission bell housing in accordance with claim 1 in which the step of selecting an aluminum alloy includes selecting an alloy of aluminum having at least 5% silicon. 
     
     
       6. A method of making an engine transmission bell housing in accordance with claim 5 in which the step of selecting an aluminum alloy includes selecting an alloy of aluminum having iron, copper, and tin alloyed therewith. 
     
     
       7. A method of making an engine transmission bell housing in accordance with claim 1 in which the step of making a pattern for casting a bell housing includes making a pattern having a flange having an irregular shape with extended cusps selected to cover bolt holes in each of a plurality of different engines. 
     
     
       8. A method of making an engine transmission bell housing in accordance with claim 1 in which the step of selecting an aluminum alloy includes selecting an alloy of aluminum having between 0.10 and 10 percent zinc. 
     
     
       9. A method of making an engine transmission bell housing in accordance with claim 1 in which the step of selecting an aluminum alloy includes selecting an alloy of aluminum having between 0.25 and 8 percent silicon. 
     
     
       10. A method of making an engine transmission bell housing in accordance with claim 8 in which the step of selecting an aluminum alloy includes selecting an alloy of aluminum having between 0.10 and 2 percent iron. 
     
     
       11. A method of making an engine transmission bell housing in accordance with claim 9 in which the step of selecting an aluminum alloy includes selecting an alloy of aluminum having between 0.2 and 1 percent copper. 
     
     
       12. A method of making an engine transmission bell housing in accordance with claim 11 in which the step of selecting an aluminum alloy includes selecting an alloy of aluminum having between 0.2 and 0.5 magnesium.